Device for cutting sheetrock

ABSTRACT

A device for cutting a substrate including a frame with a first cutting mechanism operatively connected to the frame. The first cutting mechanism is slidable in a first direction relative to the frame. The device further includes a second cutting mechanism operatively connected to the frame, which is slidable in the first direction as well as slidable in a second direction relative to the frame. The second direction is substantially perpendicular to the first direction. The first and second cutting mechanisms are adjustable to select a desired cut depth and a thickness of a substrate such that the frame may be moved along an edge of the substrate to remove excess material from the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 60/895159, filed on Mar. 16, 2007, which is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a device for cutting sheetrock orsimilar material. More particularly, the present invention relates to adevice for cutting sheetrock wherein the device may be adjustedvertically and horizontally so that a piece of sheetrock may be cut at adesired location by sliding the device across the edge of the sheetrock.

BACKGROUND OF THE INVENTION

Traditional methods for cutting sheetrock are difficult, time-consuming,and prone to error. First, the person cutting the sheetrock has tomeasure the location to be cut at several points so that an accurate andstraight cut can be made. Then, the cut needs to be made. Any error inmeasurement or cutting renders the sheetrock unusable, which increasescosts.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a device for cuttingsheetrock.

An additional object of the present invention is to provide a device forcutting sheetrock that creates more accurate cuts and is lesstime-consuming than traditional methods.

It is yet another object of the present invention to provide a devicefor cutting sheetrock that creates accurate cuts and saves time throughthe use a device that may be adjusted vertically and horizontally.

It is an additional object of the present invention to provide a devicefor cutting sheetrock that may be slid across an edge of a piece ofsheetrock to remove the edge.

An embodiment of the inventive device includes a frame with a firstcutting mechanism operatively connected to the frame. The first cuttingmechanism is slidable in a first direction relative to the frame. Thedevice further includes a second cutting mechanism operatively connectedto the frame, which is slidable in the first direction as well asslidable in a second direction relative to the frame. The seconddirection is substantially perpendicular to the first direction. Thefirst and second cutting mechanisms are adjustable to select a desiredcut depth and a thickness of a substrate such that the frame may bemoved along an edge of the substrate to remove excess material from thesubstrate.

These and other objects of the present invention will be betterunderstood in view of the Figures and preferred embodiment described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a device for cutting sheetrock accordingto an embodiment of the present invention.

FIG. 2 is a partially sectioned, perspective view of a device forcutting sheetrock, according to another embodiment of the presentinvention.

FIG. 3 is an exploded view of the device for cutting sheetrock shown inFIG. 1.

FIG. 4 is an exploded view of the device for cutting sheetrock shown inFIG. 2.

FIG. 5 is a perspective view of an ergonomic handle usable with theembodiments of FIGS. 1 and 2.

FIG. 6 is a front view of a panel of sheetrock placed within the devicesof FIGS. 1 and 2.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows one embodiment of the present invention, a device 10 forcutting sheetrock. The device 10 includes a substantially U-shaped frame12 having a bridge portion 14 and parallel arms 16 that extendhorizontally from the bridge portion 14. An adjustable post 18 and amovable post assembly 19 are assembled to the frame 12.

The bridge portion 14 defines an rectangular opening 13 for receivingthe adjusting post 18. The bridge portion 14 also includes a threadedaperture or hole 20 (best shown in FIG. 3) extending from an innersurface or face of the opening outward to an outer surface of the bridgeportion 14.

Each of the parallel arms 16 has a horizontal ridge 22. In oneembodiment, each horizontal ridge 22 extends from the bridge portion 14to a free end of the corresponding parallel arm 16. Each of the parallelarms 16 has a slot 24 coincident with the horizontal protrusion or ridge22. Each slot 24 is marked with measurements for indicating a horizontaldistance of the movable post assembly 19 from the adjusting post 18.

When received in the opening of the bridge portion 14, the adjustingpost 18 is slidably movable perpendicular to the parallel arms 16. Theadjusting post 18 carries a first blade 26 and is marked withmeasurements to indicate the vertical position of the first blade 26relative to the parallel arms 16. The adjusting post 18 includes avertical adjuster 28 for securely positioning the first blade 26relative to the frame 12, so that the first blade 26 will score or cutthe sheetrock at a first desired position. Preferably, as shown in FIGS.1 and 2, the first blade 26 is rotatably mounted to the post 18 by ascrew or similar threaded fastener. Optimally, the cutting edge of thefirst blade 26 protrudes from the adjusting post 18 about one-sixteenthof an inch ( 1/16″), as best shown in FIG. 1. Alternatively, the firstblade 26 may be fixedly mounted to the post 18, or may be formedintegral with the post 18.

In a simple embodiment of the vertical adjuster 28, the hole 20 is athreaded hole and the threaded post of the dial 34 is movable toward andaway from the adjusting post 18 by rotation of the threaded post in thethreaded hole 20, thereby clamping or releasing the adjusting post 18for vertical sliding motion within the opening 13 of the bridge portion14.

In another embodiment, the vertical adjuster 28 includes a verticalT-grooved slot (not shown), a nut housed in the slot and slidablymovable along the slot, and the vertical-adjust dial 34 having athreaded post extending through the hole 20 of the bridge portion 14.When the adjusting post 18 is received between the parallel arms 16, theT-grooved slot is aligned with the hole 20 and the threaded post of thevertical-adjust dial 34 accordingly cooperates with the threads of thenut to clamp the adjusting post 18 against the bridge portion 14 of theframe 12 by action of the nut in the slot. Thus, when thevertical-adjust dial 34 is operated to clamp the adjusting post 18, thefirst blade 26 is securely positioned relative to the parallel arms 16.When the vertical-adjust dial 34 is operated to release the adjustingpost 18, the first blade 26 is slidably vertically movable perpendicularto the parallel arms 16.

In yet another embodiment, the vertical adjuster 28 includes a toothedrack (not shown) that is slidably movable within the adjusting post 18,and that is securely positioned by meshing of the teeth with a splinedshaft of the vertical-adjust dial 34. When the adjusting post 18 isreceived between the parallel arms 16, the toothed rack is verticallymovable perpendicular to the parallel arms 16. The first blade 26 isfixedly mounted on an end of the toothed rack protruding from theadjusting post 18, for example by a screw, by adhesive, or by integralforming of the first blade 26 on the toothed rack. Accordingly, thefirst blade 26 is vertically adjusted perpendicular to the parallel arms16 by operation of the dial 34.

Referring now to FIGS. 1 and 3, the movable post assembly 19 carries asecond blade 38 for scoring the sheetrock at a second desired positionon a face of the sheetrock opposite the first desired position. Thesecond blade 38 is rotatably mounted to the movable post assembly 19.The movable post assembly 19 also has two horizontal grooves 40 forengaging with the corresponding horizontal ridges 22 of the parallelarms 16. The movable post assembly 19 includes a horizontal and verticalpositioner 42 for vertically and horizontally positioning the secondblade 38 relative to the frame 12. Like the adjusting post 18, themovable post assembly 19 is marked with measurements indicating avertical position of the second blade 38 perpendicular to the parallelarms 16. A horizontal distance between the adjusting post 18 and themovable post assembly 19 along the parallel arms 16, as indicated by themeasurements marked along the slot 24, corresponds to a thickness of thesheetrock to be scored or cut using the device 10.

The movable post assembly 19 further includes a rectilinear frame 62having two outer faces 48 in which are formed the horizontal grooves 40for mating with the horizontal ridges 22. The frame 62 also has innerfaces 50 opposed to the outer faces 48, inner faces 64 substantiallyperpendicular to the inner faces 50, and outer faces 65 opposed to theinner faces 64. A hole 54 extends from one of the horizontal grooves 40to the corresponding inner face 50, and a hole 55 extends from one ofthe outer faces 65 to the corresponding inner face 64. Vertical faces 56and 66 of the central block 46 abut and slide against the inner faces 50and 64. Again, the second blade 26 is mounted to the central block 46.

The horizontal and vertical positioner 42, as shown in FIGS. 1 and 3,includes the dial 68 mounted on a threaded shaft 74 that extends throughthe slot 24 to cooperate with threads of the hole 54 in the frame 62 fordrawing the frame 62 toward the parallel arm 16 a, thereby clamping theframe 62 to prevent motion along the parallel arms 16. The horizontaland vertical positioner 42 also includes a dial 76 having a threadedshaft 77 that cooperates with threads of the hole 55 in the frame 62 forclamping the central block 46 against motion perpendicular to theparallel arms 16.

Thus, the horizontal and vertical positioner 42 is operable to preventmotion of the movable post assembly 19 and of the second blade 26relative to the frame 12. In another version of the horizontal andvertical positioner 42, a vertical groove is formed in one of thevertical faces 66 of the central block that is disposed closest to theparallel arm 16 a. The vertical groove has a T-section and thehorizontal and vertical positioner 42 includes a nut captured andslidably movable within the vertical T-groove. When the dial 68 isoperated to tighten the horizontal and vertical positioner 42, thecentral block 46 is drawn toward the parallel arm 16a by action of thenut in the T-groove, thereby clamping the frame 62 and securelypositioning the movable post assembly 19 and the second blade 26relative to the frame 12. When the dial 68 is operated to loosen thehorizontal and vertical positioner 42, the central block 46 is releasedto slide vertically within the frame 62, and the frame 62 is released toslide horizontally along the ridges 22, thereby permitting the secondblade 26 to be positioned relative to the frame 12.

In an alternative embodiment shown in FIGS. 2 and 4, the movable postassembly 19 includes two slides 44 and a central block 46 to which thesecond blade 38 is mounted. Each of the slides 44 has an outer face 48abutting one of the parallel arms 16, on which the horizontal groove 40is formed, and an inner face 50 abutting the central block 46, on whicha vertical ridge 52 is formed. A slotted through-hole 54, as best shownin FIG. 4, is formed in each slide 44 extending from the horizontalgroove 40 to the vertical ridge 52. The central block 46 has twoopposing faces 56 abutting the two slides 44. In each opposing face 56is formed a vertical groove 58 that slidably mates with thecorresponding vertical ridge 52. A vertical slot 60 extends through thecentral block 46 perpendicular to the opposing faces 56, and is alignedwith the holes 54 when the central block 46 is assembled to the slides44.

The horizontal and vertical positioner 42, as shown in FIGS. 2 and 4,includes a dial 68 mounted on a threaded shaft 70 that extends throughthe slots 24 of the parallel arms 16, through the vertical slot 60 ofthe central block 46, and through the slotted holes 54 of the slides 44to cooperate with a clamping means 72 associated with the parallel arm16 b. In a simple version of the first embodiment, the clamping means 72is a nut slidably abutting on a surface of the arm 16 b opposed to thehorizontal ridge 22 of the arm 16 b.

When the dial 68 is operated to tighten the clamping means 72, the twoparallel arms 16 are drawn together to clamp therebetween the slides 44and the central block 46, thereby securing the movable post assembly 19and the second blade 26 relative to the frame 12. Loosening thehorizontal and vertical positioner 42 enables the slides 44 to be movedhorizontally along the ridges 22 and enables the central block 46 to bemoved vertically along the grooves 52, thereby permitting the secondblade 26 to be positioned relative to the frame 12.

Optionally, each of the parallel arms 16 can have a removable pin 80 setinto a hole formed on the horizontal ridge near the free end of the arm16, so that post assembly 19 cannot slide out of frame 12 even if thehorizontal and vertical positioner 42 accidentally is removed from theslot 24.

Many materials, including wood, thermoplastic, and metal, are suitablefor making the frame 12, the adjusting post 18, and the various parts ofthe movable post assembly 19. The adjuster 28 and the positioner 42should be made from a sturdy material durable for frequent operation.The first and second blades 26, 38 should be made from a tough and hardmaterial suitable for scoring sheetrock and suitable for holding anedge. Hard woods such as oak, hard thermoplastics such as polycarbonateor polyvinyl chloride, and many various metals are suitable for makingthe first and second blades 26, 38.

FIG. 4 shows an ergonomic handle 82. The handle 82 can be mounted to theframe 12 by various means. In one embodiment, the handle 82 comprises abase portion 84 and a grip portion 86, and is mounted to the frame 12 byscrews 88 inserted through holes formed in the base portion 84. Althoughthe handle can be made of various materials, it is preferred that thebase portion 84 be formed of a sturdy material such as metal or hardplastic, and that the grip portion 86 comprise a cushioning materialsuch as rubber or thermoplastic foam.

In operation, an edge of a sheetrock panel is placed in between theadjustable post 18 and movable post assembly 19 such that the panel edge104 abuts the underside of the parallel arms 16 a, 16 b. The adjuster 28and the positioner 42 are operated to position the first and secondblades 26, 38 at a desired cut depth 100 (indicated on the verticalmeasurement marks of the posts 18 and 19) and at a thickness of thepanel 102 (indicated on the horizontal measurement marks of the parallelarms 16). The device 10 is then dragged along the edge in a smoothmotion. The first and second blades 26, 38 drag along opposing faces ofthe panel, thereby scoring or cutting the panel at the desired cutdepth.

While the invention has been described with reference to the preferredembodiments, it will be understood by those skilled in the art thatvarious obvious changes may be made, and equivalents may be substitutedfor elements thereof, without departing from the essential scope of thepresent invention. Therefore, it is intended that the invention not belimited to the particular embodiments disclosed.

1. A device for cutting a substrate, said device comprising: a frame; afirst cutting mechanism operatively connected to said frame, said firstcutting mechanism being slidable in a first direction relative to saidframe; a second cutting mechanism operatively connected to said frame,said second cutting mechanism being slidable in said first direction aswell as slidable in a second direction relative to said frame, whereinsaid second direction is substantially perpendicular to said firstdirection; and wherein said first and second cutting mechanisms areadjustable to select a desired cut depth and a thickness of a substratesuch that said frame may be moved along an edge of said substrate toremove excess material from said substrate.
 2. The device of claim 1further comprising: first and second adjustment mechanisms for securing,respectively, said first and second cutting mechanisms relative to saidframe.
 3. The device of claim 1 further comprising: a handgrip removablyattachable to said frame.
 4. The device of claim 1 wherein said firstand second cutting mechanisms are blades removably connected to firstand second posts that are slidable relative to said frame.
 5. The deviceof claim 3 wherein said frame is substantially U-shaped an includes abridge portion and two longitudinally extending arms, said bridgeportion having an opening to accept said first post and allow movementof said first post in said first direction, and said arms beingoperatively connected to said second post such that said second post iscapable of movement in both said first and second directions.
 6. Thedevice of claim 1 wherein said substrate is a panel of sheetrock.
 7. Adevice for cutting sheetrock, comprising: a frame defining a plane; afirst blade adjustably connected to the frame for motion perpendicularto the plane; a second blade adjustably connected to the frame formotion perpendicular to the plane, and for motion toward and away fromthe first blade; a first adjuster cooperating with the first blade tosecure the first blade relative to the frame; and a second adjustercooperating with the second blade to secure the second blade relative tothe frame.
 8. The device according to claim 7, wherein the frameincludes parallel arms, the second blade is connected to the parallelarms, and the second blade is movable along the parallel arms.
 9. Thedevice according to claim 8, wherein at least one of the parallel armsis marked with measurements indicating a distance between the firstblade and the second blade.
 10. The device according to claim 7, whereinat least one of the first blade and the second blade is rotatablyconnected to the frame.
 11. The device according to claim 7, wherein atleast one of the first blade and the second blade is connected to theframe by a movable post marked with measurements.
 12. A method forcutting a panel of sheetrock, comprising: selecting a cut depthcorresponding to a distance measured from an edge of the panel;adjusting two opposed blades to provide the selected cut depth; bringingthe two opposed blades in contact with opposed faces of the panel; andmoving the two opposed blades along the opposed faces of the sheetrockparallel to the edge of the panel.
 13. The method according to claim 12,further comprising: breaking the panel at scored lines made by the twoopposed blades.